Fibrous sound producing means and mfthod of producing the same



March 27, 1934.y ,La HAWLEY 1,952,159

FIERoUs sQuMD PE'oDucIMG MEANS AND METHOD OE PRoDEcING vTHE sAME FiledJuly 2?, 1931 3 Sheets-Sheet l AVA f/n A 1 A E l l/ f March 27, 1934. J.B. HAwLEY FIBI'OUS SOUND PRODUCING MEANS AND METHOD 0F PRODUCING THESAME TQS March 27, 1934.

J. B. HwLEY vEnmous somm PnoDUcING MEANS AND METHOD oF PRODUGING THESAME 5 Sheets-Sheet 3 Filed July 27, 1931 30 affecting the pliabilityand suppleness of that brous material;

latenteclxM'ar. 27,

UNITED sTATEs-PATENtoFl-ic ,FIBROUS SUND PBODUCING'MEANS AND MF-Tl-IOD0F PBODUCING- THE SAME Jesse, B. Hawley, Geneva, Ill. Application July27, 1931, Serial No.A 553,296

1s claims. (Cl. :az-51) i 'f 'I he present invention relates toflbrous'sound by the invention as will later appear, and as areproducing means and the method ofproducing 'inherently possessedthereby. the same. v Referring to the drawings:

. Among the objects of the invention is to pro- Fig.' 1 isga'fragmentary sectional view of a l vide a novel sound producing membercomposed porous former and ablanking-off means on apart of conjoinedstrata of diilerent kinds of fibrous of a previously deposited stratum`of hard fibrous materials, such as soft and hard fibres, the ma.-material, and alsoshowing a deposit of a stratum terial being preferablyaccreted and integrated of soft fibrous material; to form an unitaryintegral member or unit. The Fig. 2 is a similar view showingtheblankingmember may be of the diaphragmatic type having oil of thestratumof soft brous material and 55 a vibratile portion, such as a coneshaped part, the further deposit of hard fibrous material on andasupporting portion, such as a border or the previously deposited stratumthereof;

marginal part adapted to be secured to a frame Fig.. 3 is a similar viewshowing a completed or similar supporting means. integrated unitarymember before it is stripped l5 The supporting portion is designed to befiexfrom the porous former; 70 ible, pliable, and supple to affordunimpeded free- Fig. 4 is a similar view showing the blankingdom ofmovement of the vibratile part when vioff of a central portion of theporous former brated, while the vibratile portionis suiiiciently and thedepositing of a thin border stratum of stiff or rigid to maintain itsshape whenjactuatedv hard' brous material; y

to propagate or generate'sound. The strata of Fig.5 is a similar viewshowingthe blanking- 75 the supporting `or bordir Iportion arepredomiloi of the border stratum shown deposited in Fig. nantly of softfibrousmaterial, such as textile 4, and the depositing of a thickstratum of hard fibres, as wool, cotton; linen, and the `like so asfibrous material anda thin stratum of soft fibrous to give the border orsupportingportion pliability material on' the centralportion of theformer;

and suppleness. Fig. 6 is a similar view showing the blanking- Theremainder 'of the border portion may be of oi of the central strata ofhard and soft fibrous harder or tougher fibrous material, such as woodmaterials shown deposited in Fig. 5, and the de- 'Y pulp, paper pulp,and the-like, so as to give the' lpositing of a thick border stratum ofsoft fibrous border portion durability or toughness, yet not materialand a thin border stratum of hard ii- 85 part. A A Fig. 'lis a similarview showing the blanking- The vibratile portion is designed to besuflioil of thick and thin border strata shown deposciently rigidorstiff to sustain the load of propaited-in Fig. 6, and the4 depositing ofathick'central gating or generating sound or sound waves, withstratum ofhard fibrous material;

out distortion, and without strains, the strata of Fig. Bis asimilarview showing the blanking- 90 1 this portion being predominantly of theharder or off of a border portion of the porous former, and tougherfibres, such as wood pulp, paper pulp, the -depositing of a thin stratumof soft fibrous and the like, the remainderof the strata being materialon the exposed portion of the porous of softer fibres so as to give tothe vibratile por former;

40A tion some resiliency and to reduce or eliminate Fig. 9 is a similarview showingthe blanking- $5 parasitic resonance and the like, withoutaffecting 1T 01; the deposit ShOWD in F18- 8, and the d ethe stiffnessof the vibratile portion as a whole. DOS'JIISv 0f a thick Stra-tum 0fSoft brous ma- Another object ofthe invention is to provide a telfial 0nuw exposed bordel' Portion. the

` novel process 'for producing the above mentioned fonnerf and 5.150 9'deposit 0f a thm stratum 0f m0 article. The various strata or layers o'rlamin l'fglsrllsmelalflwn sid thick stratum are alternately deposlted,accreted and inte Fig. 1o. is a similar View showing the b1 .l I gratedP0 a Prus ffmer"b1ank1ng means off of the border strata and the depositif u being used to blank off a portion of the former ng o thick stratumof hard fibrous material, and a thin or previously deposited` fibrousmaterial, when stra-tum of son nbrous material. and 105 l depositingother fibrous material on the exposed Fig 11 is a similar View showin'g-the'bmukmg part of the former or previously deposited fibrous off ofthecentral Snam-UA and the depositing of mtefalf' l thick 'stratum of softfibrous material.

Otherobjects, advantages, capabilities, process Referring now more indetail to the drawings, steps, and structural features are comprehendedthe invention is practiced inconnection with a 'no' porous formercomprising a plate 1 having a central conic portion 2, a marginal orborder portion 3, and an intermediate rolled or undulated portion 4. Atthe edge, this plate has a flange 5 adapted to rest upon a table (notshown) capable of being lowered into a fibrous bath for submerging orimmersing the former, and of being raised out of the bath after depositof nbrous material on the former from the bath. Any suitable means maybe used to effect such immersion into and withdrawal from a bath.

To the table may be connected a suitable suction duct whereby suction ora partial vacuum may be effected in a chamber 6 deiined bythe table,flange 5,- and plate 1. i

The plate 1 has a largenumber of apertures or holes 7 for the passage orthe fluidal vehicle or medium, such as water, of the bath. The uppersurface of the plate l is preferably formed with grooves 8 which giveinto the drain holes 7.

Upon the ridges 9 of the plate 1 may rest a thin plate 10 having aninnumerable number of ne holes or pores l1. ,Upon this plate 10 mayresta .reticulated or foraminous member 12, al

'though this member may be .omitted if desired and the plate l0 be usedto perform the function of member l2. The use of the member 12 sometimesfacilitates the stripping of the wet brous blank, although the strippingof such a blank from the plate 10 is practical, when the member -12 isomitted.

When it is desired to make a diaphragmatic sound producing member withthe vibratile or conic portion entirely of hard fibrous material, suchas wood or paper pulp, and the supporting or border portion mainly ofsoft fibrous material, such as textile fibres, as wool and the like, andpartly of hard or tough brous material, as wood or paper pulp, theprocess used is illustrated in Figs. l, 2 and 3 of the drawings.

The former is iirst submerged in a pulp bath, and with the suctioneffective in the chamber 6, the water of the bath is drawn through theinterstices of the member 12, the holes 11 of plate 10, grooves 8 andholes 7 of plate 1 and thence to the suction duct. This effects adeposit, accretion ,and integration of pulp bres into a thin stratum 13over the surface of the, porous member 12.

With the suction i Ibeing still eifective, the former and table areraised out of the bath, and then a stopper plate or blanking-ofi member14 having a conic portion 15 and a curved or curled border portion 16shaped to conform with a part of the 4undulated or intermediate portion4 of the plate, vis placed upon the conic or vibratile portion 17 and apart 18 of the juncture or intermediate portion 19 of the pulp blank 13.The border portion 20 of this blank, as also the remainder 21 of thejuncture 1 9, are left exposed.

The former is now immersed in a brous bath of soft fibres, such as wool,cotton, or the like, so that a thick stratum 22 of s oft brou's materialis deposited, accreted and integrated upon and with the exposed borderportion 19 and curved part 21 ofthe blank, thus forming a border stratumportion 23 and a curved juncture stratum part 24. 'The hard and softbres knit together and are infused and integrated so that there is anunitary integral mass composed of different strata of fibrous materialwith no demarcation or cleavage. The former -is then raisedout of thisbath. See Fig. 1.

The blanking member 14 is then removed, and another blanking member 25comprising a border blanking oi portion 26 and a curved orlcurledYstratum portion 29 and -juncture stratum part 30, is deposited,accreted upon,l and integrated and united with the stratum 17 and theinner edge portion 31 of the stratum 22 of the border portion of theblank. See Fig. 2.

so l' The blanking-oi member 25 may then be removed, and the deviceagain submerged in the pulp bath to deposit a thin stratum 32 to thefull extent of the blank, this stratum comprising a conic stratumportion 33, border stratum portion 34, and juncture stratum portion 35.The

stratum 32 is deposited and accreted upon, and is integrated, infusedand knitted with the conjoint strata 28 and 22, so as to form an unitaryintegral brous blank, as clearly shown in Fig. 3.l

The various strata are so blended together that there is a continuity ofmaterials without demarcation, yet one portion, such as the conic orvibraN tile portion, is mainly of pulp fibres, and another portion, suchas the border of supporting portion,. is predominantly of soft ortextile fibres; such as wool, cotton, flax, etc., the thin strata ofpulp iibres in this portion giving the border portion durability andresilience without detractlng from the pliability and suppleness of thisborder portion,

The blank, thus produced, may be stripped from the mold or former, as byair pressureacting through the former to blow off the blank or bysuction above the blank and former to lift otl` the blank. The blank maythen be compressed, if desired, dried, and treated with suitablematerials such as latex for proofing thediaphragm against moisture andother climatic conditions, and also other treating substances, aslacquer,

and the like for adding stiffness to the conic portion, or othercharacteristics or properties as desired.

In use the diaphragm is supported by way of the border portion which maybe held between clamping means or the like, and the apicalpart of theconic portion is suitably connected to an electrical actuator or driver,or carries a voice coil operatively located in an electrodynamic gap.The conic portion vibrates to produce sound, and part of the borderportion and the juncture between the border portion and the conicportion flexes pliably to permit free movement of the vibratile conicportion of the diaphragm.

The form above disclosed comprises a conic vibratile portion wholly ofpulp iibres, and the border or supporting portion mainly of soft fibreswith laminas of harderflbres, as at the surfaces thereof, but the blankmay be made with any number of strata of hard and soft fibres withvarying degrees of thickness in the different por tions of thediaphragmatic member.

In Figs. 4, 5, 6.and 7 is shownthe mode of vproducing sucha memberwhereby the vibratile por tion predominates in pulp bres with a thinstratum, as a core, of soft bres, while the border or supporting portionpredominates in soft bres l the inner edge of the border stratum 37 andthe outer edge of the portion 43 knitting, integrating, and uniting tolform a continuous integral stratum.v See Fig. 5.

'I'he device is then raised out of the pulp bath,

l and is then submerged into another bath of soft fibrous material forthe depositing of a thin stratum 44 on the exposed conic portion of thestratum 42 as .clearly shown in Fig.f5. The stratum 44 accretes upon andintegrates with the stratum 42 to form an unitary integral mass ofmaterials.

After raising the device from the bath, the blanking-off member isremoved and another blanking-oi member 45 is placed upon the conicportion of the blank, as on the stratum 44. The

member has a curled border 46 which is disposed in tapered spacedrelation over the stratum portion 43 so'as to provide a beveled splicingspace 47 between the part 46 and the stratum portion 43. See Fig. 6.

The device is then submerged in a bath of soit fibrous material and athick stratumv 48 is den posited and accreted upon, and integrated andunited with the stratum 37 and stratum portion 43 to form an integralunited mass of materials,

` the` soft bres also accreting in the space 47 and forming a beveledsplicing portion 49 which is also integrated and united with the pulpportion 43 as valso with the edge portion of the stratum 44. See Fig. 6.

soft ilbrous material, and then submerged in a bath of harder brousmaterial, such as pulp, and a thin stratum '50 of pulp is depositedaccreted upon and integrated and infused-with the stratum 46.` See Fig.6.

Then, the device, is raised out of the bath, the blanking-ofr member 45removed, and the blanking-oi member 38a may then be placed upon thestratum 50, the curled part 39a beingspaced above 50 the stratumportion49 to form a beveled .or splice ing space 5l.

The device is then submerged in a pulp bath whereupon a thick stratum 52of pulp is deposited and accreted upon and integrated and infused withthe stratum 44 and stratum portion 49, the

brous material entering into the space 5l to accrete thereon and tointegrate with the tapered stratum part 49 and also to integrate andunite with the inner edge portion of stratum 50. SeeA v Fig. 7.

.rials with varying degrees of hard and soft fibres.

' The blank may then be removed and nished as above mentioned inconnection with the articles shown in Figs. 1, 2 and 3fy If desired. thestrata may be arranged convers'ely to that shown in Figs. 4, 5, 6 and 7,as

.shown in Figs. 8, `9, 10 and 11.

In this case` a bl'anking-off member 5l having a curved portion 52 isfirst placed upon the border and juncture portions of the former, andthen *.75 l the devicevis submerged into al bath of soft fibrous lThedevice is then raised vfrom the bath of material to depositand accreteupon the exposed conic portion of the former, a thin stratum 53 of softbrous material. See Fig. 8.

After raising the device out of the bath and removingthe blanking-offmember 51, another blanking-off member 54 having a curled portion 55, isplaced upon the stratum 53 with the part 55 in tapered spaced relationwith the juncture portion 40 of the former so as to form a beveled space56 between parts 55 and` 40.

The device is then submerged into a bath of lsoft fibrous materialwhereupon 'a thick stratum 57 with a beveled splicing stratum portion`58 is deposited and accreted upon the exposed parts of the former, andintegrated, united and infused with the outer edge portion of thestratum 53. See Fig. 9. v.

The device is then raised from the bath and then submerged into a bathof hard brous material, such as pulp, to form a thin stratum 59 which isdeposited and accreted upon and integrated,

vinfused and united with the exposed portion of stratum 57. See Fig. 9.

After raising the device from this bath, the blanking-oi member 54 isremoved, and another blanking-oi member 60 having a curled portion 6l,is then placed upon the stratum 59 with the curled part in taperedspaced relation above the splicing lstratum portion 58 to form a beveledspace 62 `between part 6l and stratum portion 68.

The device is then submerged into the pulp bath, and a thick stratum 63of pulp is deposited and accreted upon the exposed stratum 53 and in thespace 62 to form a tapered stratum portion 64, and also is integrated,united and infused with the stratum 53 and stratum portion 58, and alsowith the inner edge portion of the stratum 59. See Fig. 10.

The device may then be 4submerged into a bath of soft fibrous materialto form a thin stratum 65 deposited and accreted upon and integrated,united and infused with stratum 63.

After raising the device from this bath, the blanlring-off member 60 isremoved and blanking-oli ymember 54a is placed upon stratum 65, Withthecurled part 55a in tapered spaced relation over the beveled splicingstratum portion 64, to form a beveled splicing space 66 between part 55Land stratum portion 64.

The device is then submerged in a bath of soft iibrous material to forma thick lstratum 67 with a beveled splicing stratum portion 68 in thespae 66, which are deposited and accreted upon Vstraturn 59 and stratumportion 64 and in space 66, and also integrated, united and infused withstratum 59, stratum portion 64, and the outer edge portion of stratum65. The device may then be raised out of the bath and the blanking-offmeme ber 54a removed. See Fig. ll. In this way the blank is composed ofdiierent materials in vary ing degrees of thicknesseawith apreponderance of 4pulp er like fibrous material in the conic orvibratile portion,- and a Vpreponderance of soft :dbrous material intheborder or supporting portion, all integrated, united, infused andknitted i together to form an unitary integral blank.

The blank may then be removed, dried, and treated as above described.

By'using blanking-ol members with curled borders, to provide taperedspaces Ytherebeneath, g

- and juncture portions of the unit whereby the .to produce sound.

While I have herein described and upon the drawings shown a fewillustrative embodiments of' the invention and a few methods ofproducing the same, it is to be understood that the invention is notlimited thereto but comprehends other constructions, compositions,details, arrangements of' parts, features, and process steps withoutdeparting from the spirit of the invention. Any number` of strata ofmaterials may be accreted and integrated in accordance with the mannerof this invention, without limit. As for example, the unit shown in Fig.7 may have one or more thin strata of soft fibres and one or more thickstrata of hard fibres in the conic portion, and one or more thick strataof soft fibres, and one or more thin strata of hard fibres in the borderportion of the unit. Likewise, the unit shown in Fig. 11 may have one ormore thick strata of hard fibres, and one or more thin strata of softfibres in the conic portion, and one or more thin strata of hard fibres,and one or more thick strata of soft fibres in the border portion of theunit.

Having thus disclosed the invention,

I claim: A

1.V A vibratile sound producing member of diaphragmatic type comprisingintegrated strata of different fibrous materials.

2.- A vibratile sound producing member of diaphragmatic type comprisingintegrated strata of alternate grades of fibrous materials.

'3. A vibratile sound producing member of diaphragmatic type comprisingintegrated strata of plant fibrous material and animal fibrous material.

fi. A vibratile sound producing member of diaphragmatic type comprisingintegrated strata of soft fibrous material and hard fibrous material.

5. A vibratile sound producing member of diaphragmatic type comprisingintegrated strata of pliable fibrous material and stiff fibrousmaterial.

6. A vibratile sound `producing member of diaphragmatic type comprisingintegrated strata of pulp fibres and textile fibres.

7. A sound producing diaphragmatic member, comprising a vibratileportion and a supporting portion, said vibratile portion being composedof integrated strata of different fibrous materials, and said supportingportion being pliable for af fording free movementof said vibratileportion.

8. A sound producing diaphragmatic member, comprising a vibratileportion and a supporting portion, said vibratile portion being composedof integrated strata of soft and hard fibrous materials, and saidsupporting portion being pliable for affording free movement of saidvibratile portion.

9. A sound producing diaphragmatic member, comprising a vibratileportionand a supporting portion, said vibratile portion being composedof integrated strata of soft .and hard fibrous materials, the hardfibrous material predominating to give said vibratile portion stiffnessfor propagation of sound when vibrated, and said supporting portionbeing pliable for affording free movement of said vibratile portion.

10. A sound producing diaphragmatic member,

comprising a vibratile portion and a supporting portion, said supportingportion being composed of softand hard fibrous materials, the softfibrous A in the supporting portion to give it suppleness and the hardfibrous material predominates in the vibratile portion to give itstiffness, said portions beingintegrated at their juncture.

12. A sound producing diaphragmatic member comprising a vibratileportion and a supporting portion, said vibratile portion comprising athick stratum of hard fibrous material and a thin stratum of softfibrous material integrated with said thick stratum and being stiff forpropagating sound when said vibratile portion is vibrated, saidsupporting portion comprising soft fibrous material integrated with saidvibratile portion and being supple to afford freedom of movement of saidvibratile portion when vibrated.

13. A sound producing diaphragmatic member comprising a vibratileportion and a supporting portion, said supporting portion comprising athick stratum of soft fibrous material and a' thin stratum of hardfibrous material integrated with said thick stratum and being supple toafford freedom of movement of said vibnatile portion when vibrated, saidvibratile portion comprising hard fibrous material integrated with saidsupporting portion at their juncture and being stiff for propagatingsound when said vibratile portion is vibrated.

14. Asound producing diaphragmatic member comprising a vibratile portionand a supporting portion, said vibratile portion comprising a thickstratum of hard fibrous material and a thin stratum of soft fibrousmaterial integrated with said thick stratum andbeing stiff forpropagating sound when said vibratile portion is vibrated, saidsupporting portion comprising a thick stratum of soft fibrous materialand a thin stratum of hard fibrous material integrated with said thickstratum and being supple to afford freedom of movement of said vibratileportion when vibrated, said vibratile and supporting portions beingintegrally united at their juncture.

15. In a process of making a'fibrous sound producing member, the stepsof accreting and integrating conjunctive strata of different kinds offibrous materials, including the blanking-off of a portion while causingthe accretion and integration of another portion.

16. In alprocess of making a fibrous sound producing member, the stepsof accreting and integrating conjunctive strata of different kinds offibrous materials on different portions of a porous former, includingfirst accreting and integrating one portion while blanking-off anotherportion, and then accreting and integrating another p0rtion whileblanking-off the said one portion.

17. In a process of making a fibrous sound producing member, the stepsof accreting and integrating adjunctive strata of soft and hard fibrousmaterials, and accreting and integrating therewith respectively andtogether adjunctive strata of hard and soft fibrous material, to form anunitary stratified integral member.

18. In a process of making a fibrous sound producing member comprising avibratile portion and a supporting'portion, the steps of forming thevibratile portion with accreted and integrated strata of different kindsof fibrous materials, forming the supporting portion with accreted andintegrated strata of different kinds of brous materials, and integratingsaid portions at their juncture.

19. In a process of making a fibrous sound producing diaphragmaticmember having a, viloratilev portion and a supporting portion, the stepsof accreting and integrating thin and thick strata of soft and hardfibrous materialsvrespectiveiy,

.accreting and integrating thick and thin strata

